Custom Orthopedic Braces via Photogrammetry and Modular Design
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Solution Overview
Problem
Traditional braces and casts face limitations in accuracy, comfort, and efficiency due to generic sizing and labor-intensive custom manufacturing processes, which result in inadequate control, skin issues, and high costs associated with frequent replacements and sedation requirements, especially for pediatric patients.
Innovation Solution
A photogrammetry-based process for fabricating custom braces and casts using surface data from patient scans, allowing for accurate measurement and design of personalized devices with modular components for growth and hygiene access, reducing the need for sedation and minimizing trauma during application and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If off-the-shelf braces with generic sizing are used, then cost is reduced and availability is improved, but manufacturing precision and fit accuracy deteriorate
Solution Approach 1:
The patent applies preliminary action by creating a three-dimensional digital model of the patient's body part before brace fabrication. This digital model is generated through scanning or photogrammetry methods, allowing the brace design to be precisely customized to the patient's anatomy in advance, thereby achieving both customization accuracy and manufacturing efficiency.
Solution Approach 2:
The patent uses copying by creating a digital replica or three-dimensional model of the patient's body part. This digital copy serves as the basis for designing and fabricating the custom brace, eliminating the need for physical molds or manual measurements while maintaining high precision fit accuracy.
2Manufacturing precision
If custom braces are manually fabricated, then manufacturing precision is improved, but productivity and time efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical fabrication processes with computer-aided design (CAD) and automated manufacturing systems. The three-dimensional digital model is used to generate precise digital designs that can be fabricated using automated processes such as 3D printing or CNC machining, significantly improving production speed while maintaining or enhancing fit accuracy.
3Strength
If traditional casting materials are used, then structural strength is improved, but patient comfort and breathability deteriorate
Solution Approach 1:
The patent applies local quality by varying the material properties and thickness of the brace in different regions. Areas requiring high structural strength (such as fracture sites) use denser, stronger materials, while areas contacting the skin use more breathable, comfortable materials. This localized differentiation maintains structural integrity while improving patient comfort and breathability.
Solution Approach 2:
The patent uses composite materials that combine different properties in a single brace structure. The brace may incorporate rigid materials for structural support, flexible materials for comfort, and breathable materials for skin health. This composite approach allows the brace to simultaneously achieve structural strength, patient comfort, and breathability.
4Adaptability or versatility
If pediatric patients require frequent cast replacements for growth, then adaptability is improved, but loss of time and increased cost deteriorate
Solution Approach 1:
The patent applies dynamics by designing braces with adjustable and modular components that can be modified as the patient grows. The brace structure includes adjustable straps, expandable sections, or replaceable modules that allow the same brace to adapt to changing body dimensions, eliminating the need for frequent complete replacements and reducing time loss and costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables precise, comfortable, and cost-effective custom-fit braces and casts with improved hygiene and reduced trauma, allowing for virtual fittings and modular designs that adapt to patient growth and healing stages, minimizing the need for frequent replacements and sedation.
Implementation Method 1
A photogrammetry process is used in which the surface data for a patient is obtained from a plurality of photographs of the patient
Data Source
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AI summary
A custom device and method for fabricating the custom device includes marking a body with reference points and/or other indicators. Multiple images of the body from multiple angles are then obtained. The images are used to determine the contours of the body and the other markings are located and used to design the custom device. The custom device can be fabricated as a single piece structure or in multiple pieces that are assembled to complete the custom device.